Lithium metal battery with solid polymer electrolyte

ABSTRACT

A battery comprising: an anode comprising a first electrochemically active material: a cathode comprising both a second electrochemically active material and a first electrolyte; and a second electrolyte interposed between the anode and the cathode; wherein at least one of the first electrolyte and second electrolyte comprises a solid polymer electrolyte; wherein the solid polymer electrolyte has a glassy state, and comprises both at least one cationic diffusing ion and at least one anionic diffusing ion; wherein at least one of the at least one cationic diffusing ions comprises lithium; wherein at least one of the at least cationic diffusing ion and the at least one of the anionic diffusing ion is mobile in the glassy state; and wherein the first electrochemically active material comprises a lithium metal.

FIELD OF THE INVENTION

One or more embodiments relate to electrodes including a solid polymerelectrolyte, manufacturing methods thereof, and lithium batteriescontaining the same.

DESCRIPTION OF THE RELATED TECHNOLOGY

Lithium secondary batteries, provide an energy density by generating adischarge voltage below around 4.0 Volts. However, at higher voltagesthe typical electrolytes used in these batteries can decompose and limitthe life of the battery. The electrolytes that have been developed sofar do not afford such a high state of charge, and electrolyte stabilityat satisfactory levels.

Typical electrolytes used in lithium secondary batteries also limit thetemperature range of useful performance of such batteries. A solidionically conductive polymer material with high conductivity over a widerange of temperatures, including room temperature and below has beendemonstrated to provide high performance over a wide temperature range.

The current state-of-the-art lithium ion electrode fabrication processinvolves several steps: mixing, slurry coating, drying, calendaring andelectrode finishing. Some of these steps can be eliminated by using anextruded electrode method, incorporating the solid polymer electrolyteinto the Lithium battery electrode.

The present embodiments overcome the above problems as well as provideadditional advantages.

SUMMARY OF THE INVENTION

According to an aspect, a battery comprising: an anode having a firstelectrochemically active material; a cathode having both a secondelectrochemically active material and a first electrolyte; a secondelectrolyte interposed between the anode and the cathode; wherein atleast one of the first electrolyte and second electrolyte comprises asolid polymer electrolyte; wherein the solid polymer electrolytecomprises both at least one cationic and anionic diffusing ion, whereinat least one cationic diffusing ions comprises lithium.

In the aspect, the battery the solid polymer electrolyte furthercomprises: a crystallinity greater than 30%; a melting temperature; aglassy state; and wherein at least one diffusing ion is mobile in theglassy state.

Further aspects of the battery can include one or more of the following:

The battery wherein the solid polymer electrolyte further comprises aplurality of charge transfer complexes.

The battery wherein the solid polymer electrolyte comprises a pluralityof monomers, and wherein each charge transfer complex is positioned on amonomer.

The battery wherein the electronic conductivity of the solid polymerelectrolyte is less than 1×10⁻⁸ S/cm at room temperature.

The battery wherein the solid polymer electrolyte comprises: a pluralityof monomers; a plurality of charge transfer complexes, wherein eachcharge transfer complex is positioned on a monomer; wherein theelectronic conductivity of the solid polymer electrolyte is less than1×10⁻⁸ S/cm at room temperature.

The battery wherein the crystallinity of the solid polymer electrolyteis greater than 30%.

The battery wherein the solid polymer electrolyte has a glassy statewhich exists at temperatures below the melting temperature of the solidpolymer electrolyte.

The battery wherein the solid polymer electrolyte further comprises botha cationic and anionic diffusing ion, whereby at least one diffusing ionis mobile in a glassy state of the solid polymer electrolyte, andwherein the crystallinity of the solid polymer electrolyte is greaterthan 30%.

The battery wherein the melting temperature of the solid polymerelectrolyte is greater than 250° C.

The battery wherein the solid polymer electrolyte is a thermoplastic.

The battery wherein the ionic conductivity of the solid polymerelectrolyte is isotropic.

The battery wherein the solid polymer electrolyte is non-flammable.

The battery wherein the Young's modulus of the solid polymer electrolyteis equal to or greater than 3.0 MPa.

The battery wherein the solid polymer electrolyte has a glassy state,and at least one cationic and at least one anionic diffusing ion,wherein each diffusing ion is mobile in the glassy state.

The battery wherein the ionic conductivity of the solid polymerelectrolyte is greater than 1.0×10⁻⁵ S/cm at room temperature.

The battery wherein the solid polymer electrolyte comprises a singlecationic diffusing ion, wherein the single anionic diffusing ioncomprises lithium, and wherein the diffusivity of the cationic diffusingion is greater than 1.0×10⁻¹² m²/s at room temperature

The battery wherein the solid polymer electrolyte comprises a singleanionic diffusing ion, and wherein the diffusivity of the anionicdiffusing ion is greater than 1.0×10⁻¹² m²/s at room temperature.

The battery wherein one of the at least cationic diffusing ion, has adiffusivity greater than 1.0×10⁻¹² m²/s.

The battery wherein one of the at least one anionic diffusing ion has adiffusivity greater than 1.0×10⁻¹² m²/s.

The battery wherein one of both the at least one anionic diffusing ionand at least one cationic diffusing ion has a diffusivity greater than1.0×10⁻¹² m²/s.

The battery wherein the solid polymer electrolyte has an ionicconductivity greater than 1×10⁻⁴ S/cm at room temperature.

The wherein the solid polymer electrolyte has an ionic conductivitygreater than 1×10⁻³ S/cm at 80° C.

The battery wherein the solid polymer electrolyte has an ionicconductivity greater than 1×10⁻⁵ S/cm at −40° C.

The battery wherein the concentration of lithium is greater than 3 molesof lithium per liter of solid polymer electrolyte.

The battery wherein each at least one cationic and anionic diffusing ionhave a diffusivity, wherein the cationic diffusivity is greater than theanionic diffusivity.

The battery wherein the cationic transference number of the solidpolymer electrolyte is greater than 0.5 and less than 1.0.

The battery wherein at least one diffusing anion is monovalent.

The battery wherein at least one anionic diffusing ion comprisesfluorine or boron.

The battery wherein the solid polymer electrolyte comprises a pluralityof monomers and wherein there is at least one anionic diffusing ion permonomer.

The battery wherein the solid polymer electrolyte comprises a pluralityof monomers and wherein there is at least one cationic diffusing ion permonomer.

The battery wherein there is at least one mole of the lithium per literof solid polymer electrolyte.

The battery wherein the solid polymer electrolyte comprises a pluralityof monomers, wherein each monomer comprises an aromatic or heterocyclicring structure positioned in the backbone of the monomer.

The battery wherein the solid polymer electrolyte further includes aheteroatom incorporated in the ring structure or positioned on thebackbone adjacent the ring structure.

The battery wherein the heteroatom is selected from the group consistingof sulfur, oxygen or nitrogen.

The battery wherein the heteroatom is positioned on the backbone of themonomer adjacent the ring structure.

The battery wherein the heteroatom is sulfur.

The battery wherein the solid polymer electrolyte is pi-conjugated.

The battery wherein the solid polymer electrolyte comprises a pluralityof monomers, wherein the molecular weight of each monomer is greaterthan 100 grams/mole.

The battery wherein the charge transfer complex is formed by thereaction of a polymer, electron acceptor, and an ionic compound, whereineach cationic and anionic diffusing ion is a reaction product of theionic compound.

The battery wherein the solid polymer electrolyte is formed from atleast one ionic compound, wherein the ionic compound comprises each atleast one cationic and anionic diffusing ion.

The battery wherein the charge transfer complex is formed by thereaction of a polymer and an electron acceptor.

The battery wherein the solid polymer electrolyte becomes ionicallyconductive after being doped by an electron acceptor in the presence ofan ionic compound that either contains both a cationic and anionicdiffusing ion or is convertible into both the cationic and anionicdiffusing ion via reaction with the electron acceptor.

The battery wherein the solid polymer electrolyte is formed from thereaction product of a base polymer, electron acceptor and an ioniccompound.

The battery wherein the base polymer is a conjugated polymer.

The battery wherein the base polymer is PPS or a liquid crystal polymer.

The battery wherein both the first and second electrolyte comprise thesolid polymer electrolyte, wherein the electronic conductivity of thesecond electrolyte is less than 1×10⁻⁸ S/cm at room temperature.

The battery wherein both the first and second electrolyte comprise thesolid polymer electrolyte.

The battery wherein the anode comprises a third electrolyte, and whereinthe third electrolyte comprises the solid polymer electrolyte.

The battery wherein the second electrolyte comprises the solid polymerelectrolyte and is formed into a film, wherein the thickness of the filmis between 200 and 15 micrometers.

The battery wherein the second electrochemically active materialcomprises an intercalation material.

The battery wherein the second electrochemically active materialcomprises a lithium oxide comprising nickel, cobalt or manganese, or acombination of two or all three of these elements.

The battery wherein the second electrochemically active material has anelectrochemical potential greater than 4.2 volts relative lithium metal.

The battery wherein the cathode has an electrode potential greater than4.2 volts relative lithium metal.

The battery wherein the second electrochemically active material isintermixed with an electrically conductive material and the solidpolymer electrolyte.

The battery wherein the electrically conductive material comprisescarbon.

The battery wherein the cathode comprises 70-90 percent by weight of thesecond electrochemically active material.

The battery wherein the cathode comprises 4-15 percent by weight of thesolid polymer electrolyte.

The battery wherein the cathode comprises 2-10 percent by weight of anelectrically conductive material.

The battery wherein the electrically conductive material comprisescarbon.

The battery wherein the cathode is formed from a slurry.

The battery wherein the cathode is positioned on a cathode collector.

The battery wherein the second electrochemically active materialcomprises a lithium oxide or a lithium phosphate that contain nickel,cobalt or manganese.

The battery wherein the second electrochemically active materialcomprises a lithium intercalation material, wherein the lithiumintercalation material comprises lithium.

The battery wherein the lithium intercalation material comprises LithiumNickel Cobalt Aluminum Oxide; Lithium Nickel Cobalt Manganese Oxide;Lithium Iron Phosphate; Lithium Manganese Oxide; Lithium cobaltphosphate or lithium manganese nickel oxide, Lithium Cobalt Oxide,LiTiS₂, LiNiO₂, or combinations thereof.

The battery wherein the second electrochemically active materialcomprises an electrochemically active cathode compound that reacts withlithium in a solid state redox reaction.

The battery wherein the electrochemically active cathode materialcomprises a metal halide; Sulfur; Selenium; Tellurium; Iodine; FeS₂ orLi₂S.

The battery wherein the lithium intercalation material comprises LithiumNickel Cobalt Manganese Oxide, wherein the atomic concentration ofnickel in the Lithium Nickel Cobalt Manganese Oxide is greater than theatomic concentration of cobalt or manganese.

The battery wherein the cathode is about 15 to 115 micrometers inthickness.

The battery wherein the cathode coating density in the range of 1.2 to3.6 g/cc.

The battery wherein the first electrochemically active materialcomprises an intercalation material.

The battery wherein the anode further comprises the solid polymerelectrolyte, wherein the first electrochemically active material ismixed with the solid polymer electrolyte.

The battery wherein the first electrochemically active materialcomprises lithium metal.

The battery wherein the lithium metal in the anode 20 micrometers orless in thickness.

The battery further comprising an anode current collector in ioniccommunication with the anode, wherein lithium deposits on the anodecurrent collector when the battery is charged.

The battery wherein the density of the lithium deposited on the anodecurrent collector is greater than 0.4 g/cc.

The battery further comprising an anode current collector in ioniccommunication with the anode, wherein the electrolyte is positionedadjacent the anode current collector.

The battery wherein the first electrochemically active materialcomprises Silicon, Tin, antimony, lead, Cobalt, Iron, Titanium, Nickel,magnesium, aluminum, gallium, Germanium, phosphorus, arsenic, bismuth,zinc, carbon and mixtures thereof.

The battery wherein the second electrochemically active materialcomprises an intercalation material, wherein the first electrochemicallyactive material comprises lithium metal.

The battery wherein the charged voltage of the battery is greater than4.1 volts.

The battery wherein the charged voltage of the battery is greater than4.5 volts.

The battery wherein the charged voltage of the battery is greater than5.0 volts.

The battery wherein lithium is cycled between the anode and cathode at arate greater than 0.5 mA/cm² at room temperature.

The battery wherein lithium is cycled between the anode and cathode at arate greater than 1.0 mA/cm² at room temperature.

The battery wherein the lithium is cycled between the anode and cathodefor greater than 150 cycles.

The battery wherein lithium is cycled between the anode and cathode at arate greater than 3.0 mAh/cm² at room temperature for greater than tencycles.

The battery wherein lithium is cycled between the anode and cathode at arate greater than 18.0 mAh/cm².

The battery wherein lithium is cycled between the anode and cathode at arate greater than 0.25 mAh/cm² at room temperature for greater than 150cycles.

The battery further comprising an anode current collector, whereinlithium is plated onto the anode current collector when the battery ischarged, wherein the density of the lithium plated onto the anodecurrent collector is greater than 0.4 g/cc.

The battery wherein the lithium cycling efficiency is greater than 99%.

The battery wherein the second electrolyte comprises the solid polymerelectrolyte and is formed into a film, and wherein the first electrolytecomprises the solid polymer electrolyte, whereby the second electrolyteis attached to the cathode.

The battery wherein the second electrolyte comprises the solid polymerelectrolyte and is formed into a film, and wherein the anode comprises athird electrolyte, and wherein the third electrolyte comprises the solidpolymer electrolyte, whereby the second electrolyte is attached to theanode.

In an aspect, a method of manufacturing a battery comprising the stepsof: mixing a polymer with an electron acceptor to create a firstmixture; heating the first mixture to form a reaction product comprisinga plurality charge transfer complexes; mixing at least one ioniccompound comprising lithium with the reaction product to form a solidionically conductive polymer material.

Further aspects of the method of manufacturing a battery can include oneor more of the following: The method further comprising including mixingan intercalation material with the solid ionically conductive polymermaterial to form a cathode.

The method wherein the cathode forming step further includes mixing anelectrically conductive material with the intercalation material and thesolid ionically conductive polymer material.

The method wherein the cathode forming step further comprising acalendaring step wherein the density of the cathode is increased.

The method wherein the solid ionically conductive polymer material isformed into a film to form a solid polymer electrolyte.

The method wherein the dopant is a quinone.

The method wherein the polymer is PPS, a conjugated polymer or a liquidcrystal polymer.

The method wherein the ionic compound is a salt, hydroxide, oxide orother material containing lithium.

The method wherein the ionic compound comprises lithium oxide, lithiumhydroxide, lithium nitrate, lithium bis-trifluoromethanesulfonimide,Lithium bis(fluorosulfonyl)imide, Lithium bis(oxalato)borate, lithiumtrifluoromethane sulfonate), lithium hexafluorophosphate, lithiumtetrafluoroborate, or lithium hexafluoroarsenate, and combinationsthereof.

The method wherein in the heating step the first mixture is heated to atemperature between 250 and 450 deg. C.

The method wherein the cathode is positioned adjacent an electricallyconducting cathode current collector to form a cathode assembly.

The method wherein the solid ionically conductive polymer material isformed into a film to form a solid polymer electrolyte.

The method further comprising an electrically conducting anode currentcollector and an enclosure, and further comprising an assembly stepwherein the solid polymer electrolyte is positioned between the anodecurrent collector and the cathode assembly to form a battery assembly,and the battery assembly is placed within the enclosure.

The method wherein the battery further comprises a anode and a cathode,wherein the solid ionically conductive polymer material is formed into afilm to form a solid polymer electrolyte, further comprising attachingthe film to the anode, the cathode or both the anode and the cathode.

The method wherein in the attaching step the film is coextruded witheither the anode, cathode or both the anode and the cathode.

These and other features, advantages, and objects of the presentinvention will be further understood and appreciated by those skilled inthe art by reference to the following specification, claims, andappended drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

In the drawings:

FIG. 1 is a representation of a battery cross section;

FIG. 2 is a plot of a capacity-voltage (CV) curve of a battery describedin Example 2, which is cycled at two different voltages;

FIG. 3 is cycle plot of a battery described in Example 4;

FIG. 4 is cycle plot of a battery described in Example 4;

FIG. 5 is cyclic voltammetry plot of a battery described in Example 5;

FIG. 6 is cyclic voltammetry plot of a comparative battery described inExample 6;

FIG. 7 is a representation of a test fixture cross section described inExample 7;

FIG. 8 is cycle plot of a battery described in Example 7;

FIG. 9 is electrochemical impedance spectroscopy (EIS) plot of a batterydescribed in Example 8; and

FIG. 10 is a voltage relative time plot of a battery described inExample 9.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

This application claims the benefit of U.S. Provisional PatentApplication No. 62/170,963 filed Jun. 4, 2015, now expired, herebyincorporated by reference; international application PCTUS2016035628filed Jun. 3, 2016, now expired, hereby incorporated by reference; andU.S. application Ser. No. 15/579,476 filed Dec. 4, 2017, which issued onFeb. 4, 2020 as U.S. Pat. No. 10,553,901, hereby incorporated byreference; and also incorporates by reference U.S. Provisional PatentApplication No. 62/158,841 filed May 8, 2015, now expired; U.S. patentapplication Ser. No. 14/559,430 filed Dec. 3, 2014 which issued on Aug.22, 2017 as U.S. Pat. No. 9,742,008; U.S. Provisional Patent ApplicationNo. 61/911,049 filed Dec. 3, 2013, now expired; U.S. patent applicationSer. No. 13/861,170 filed Apr. 11, 2013 which issued on Nov. 4, 2017 asU.S. Pat. No. 9,819,053; and U.S. Provisional Patent Application No.61/622,705 filed Apr. 11, 2012, now expired.

The present invention includes a lithium metal battery enabled tooperate efficiently at a high voltage by a solid ionically conductivepolymer material

The following explanations of terms are provided to better detail thedescriptions of aspects, embodiments and objects that will be set forthin this section. Unless explained or defined otherwise, all technicaland scientific terms used herein have the same meaning as commonlyunderstood to one of ordinary skill in the art to which this disclosurebelongs. In order to facilitate review of the various embodiments of thedisclosure, the following explanations of specific terms are provided:

A depolarizer is a synonym of electrochemically active substance, i.e.,a substance which changes its oxidation state, or partakes in aformation or breaking of chemical bonds, in a charge-transfer step of anelectrochemical reaction and electrochemically active material. When anelectrode has more than one electroactive substances they can bereferred to as codepolarizers.

Thermoplastic is a characteristic of a plastic material or polymer tobecome pliable or moldable above a specific temperature often around orat its melting temperature and to solidify upon cooling.

Solid electrolytes include solvent free polymers, and ceramic compounds(crystalline and glasses).

A “Solid” is characterized by the ability to keep its shape over anindefinitely long period, and is distinguished and different from amaterial in a liquid phase. The atomic structure of solids can be eithercrystalline or amorphous. Solids can be mixed with or be components incomposite structures. However, for purposes of this application and itsclaims, a solid material requires that that material be ionicallyconductive through the solid and not through any solvent, gel or liquidphase, unless it is otherwise described. For purposes of thisapplication and its claims, gelled (or wet) polymers and other materialsdependent on liquids for ionic conductivity are defined as not beingsolid electrolytes in that they rely on a liquid phase for their ionicconductivity.

A polymer is typically organic and comprised of carbon basedmacromolecules, each of which have one or more type of repeating unitsor monomers. Polymers are light-weight, ductile, usually non-conductiveand melt at relatively low temperatures. Polymers can be made intoproducts by injection, blow and other molding processes, extrusion,pressing, stamping, three dimensional printing, machining and otherplastic processes. Polymers typically have a glassy state attemperatures below the glass transition temperature Tg. This glasstemperature is a function of chain flexibility, and occurs when there isenough vibrational (thermal) energy in the system to create sufficientfree-volume to permit sequences of segments of the polymer macromoleculeto move together as a unit. However, in the glassy state of a polymer,there is no segmental motion of the polymer.

Polymers are distinguished from ceramics which are defined as inorganic,non-metallic materials; typically compounds consisting of metalscovalently bonded to oxygen, nitrogen or carbon, brittle, strong andnon-conducting.

The glass transition, which occurs in some polymers, is a midpointtemperature between the supercooled liquid state and a glassy state as apolymer material is cooled. The thermodynamic measurements of the glasstransition are done by measuring a physical property of the polymer,e.g. volume, enthalpy or entropy and other derivative properties as afunction of temperature. The glass transition temperature is observed onsuch a plot as a break in the selected property (volume of enthalpy) orfrom a change in slope (heat capacity or thermal expansion coefficient)at the transition temperature. Upon cooling a polymer from above the Tgto below the Tg, the polymer molecular mobility slows down until thepolymer reaches its glassy state.

As a polymer can comprise both amorphous and crystalline phase, polymercrystallinity is the amount of this crystalline phase relative theamount of the polymer and is represented as a percentage. Crystallinitypercentage can be calculated via x-ray diffraction of the polymer byanalysis of the relative areas of the amorphous and crystalline phases.

A polymer film is generally described as a thin portion of polymer, butshould be understood as equal to or less than 300 micrometers thick.

It is important to note that the ionic conductivity is different fromelectrical conductivity. Ionic conductivity depends on ionicdiffusivity, and the properties are related by the Nernst-Einsteinequation. Ionic conductivity and ionic diffusivity are both measures ofionic mobility. An ionic is mobile in a material if its diffusivity inthe material is positive (greater than zero), or it contributes to apositive conductivity. All such ionic mobility measurements are taken atroom temperature (around 21° C.), unless otherwise stated. As ionicmobility is affected by temperature, it can be difficult to detect atlow temperatures. Equipment detection limits can be a factor indetermining small mobility amounts. Mobility can be understood asdiffusivity of an ion at least 1×10⁻¹⁴ m²/s and preferably at least1×10⁻¹³ m²/s, which both communicate an ion is mobile in a material.

A solid polymer ionically conducting material is a solid that comprisesa polymer and that conducts ions as will be further described.

An aspect includes a method of synthesizing a solid ionically conductivepolymer material from at least three distinct components: a polymer, adopant and an ionic compound. The components and method of synthesis arechosen for the particular application of the material. The selection ofthe polymer, dopant and ionic compound may also vary based on thedesired performance of the material. For example, the desired componentsand method of synthesis may be determined by optimization of a desiredphysical characteristic (e.g. ionic conductivity).

Synthesis:

The method of synthesis can also vary depending on the particularcomponents and the desired form of the end material (e.g. film,particulate, etc.). However, the method includes the basic steps ofmixing at least two of the components initially, adding the thirdcomponent in an optional second mixing step, and heating thecomponents/reactants to synthesis the solid ionically conducting polymermaterial in a heating step. In one aspect of the invention, theresulting mixture can be optionally formed into a film of desired size.If the dopant was not present in the mixture produced in the first step,then it can be subsequently added to the mixture while heat andoptionally pressure (positive pressure or vacuum) are applied. All threecomponents can be present and mixed and heated to complete the synthesisof the solid ionically conductive polymer material in a single step.However, this heating step can be done when in a separate step from anymixing or can completed while mixing is being done. The heating step canbe performed regardless of the form of the mixture (e.g. film,particulate, etc.) In an aspect of the synthesis method, all threecomponents are mixed and then extruded into a film. The film is heatedto complete the synthesis.

When the solid ionically conducting polymer material is synthesized, acolor change occurs which can be visually observed as the reactantscolor is a relatively light color, and the solid ionically conductingpolymer material is a relatively dark or black color. It is believedthat this color change occurs as charge transfer complexes are beingformed, and can occur gradually or quickly depending on the synthesismethod.

An aspect of the method of synthesis is mixing the base polymer, ioniccompound and dopant together and heating the mixture in a second step.As the dopant can be in the gas phase, the heating step can be performedin the presence of the dopant. The mixing step can be performed in anextruder, blender, mill or other equipment typical of plasticprocessing. The heating step can last several hours (e.g. twenty-four(24) hours) and the color change is a reliable indication that synthesisis complete or partially complete. Additional heating past synthesis(color change) does not appear to negatively affect the material.

In an aspect of the synthesis method, the base polymer and ioniccompound can be first mixed. The dopant is then mixed with thepolymer-ionic compound mixture and heated. The heating can be applied tothe mixture during the second mixture step or subsequent to the mixingstep.

In another aspect of the synthesis method, the base polymer and thedopant are first mixed, and then heated. This heating step can beapplied after the mixing or during, and produces a color changeindicating the formation of the charge transfer complexes and thereaction between the dopant and the base polymer. The ionic compound isthen mixed to the reacted polymer dopant material to complete theformation of the solid ionically conducting polymer material.

Typical methods of adding the dopant are known to those skilled in theart and can include vapor doping of film containing the base polymer andionic compound and other doping methods known to those skilled in theart. Upon doping the solid polymer material becomes ionicallyconductive, and it is believed that he doping acts to activate the ioniccomponents of the solid polymer material so they are diffusing ions.

Other non-reactive components can be added to the above describedmixtures during the initial mixing steps, secondary mixing steps ormixing steps subsequent to heating. Such other components include butare not limited to depolarizers or electrochemically active materialssuch as anode or cathode active materials, electrically conductivematerials such as carbons, rheological agents such as binders orextrusion aids (e.g. ethylene propylene diene monomer “EPDM”), catalystsand other components useful to achieve the desired physical propertiesof the mixture.

Polymers that are useful as reactants in the synthesis of the solidionically conductive polymer material are electron donors or polymerswhich can be oxidized by electron acceptors. Semi-crystalline polymerswith a crystallinity index greater than 30%, and greater than 50% aresuitable reactant polymers. Totally crystalline polymer materials suchas liquid crystal polymers (“LCPs”) are also useful as reactantpolymers. LCPs are totally crystalline and therefore their crystallinityindex is hereby defined as 100%.

Undoped conjugated polymers and polymers such as polyphenylene sulfide(“PPS”) are also suitable polymer reactants.

Polymers are typically not electrically conductive. For example, virginPPS has electrical conductivity of 10⁻²⁰ S cm⁻¹. Non-electricallyconductive polymers are suitable reactant polymers.

In an aspect, polymers useful as reactants can possess an aromatic orheterocyclic component in the backbone of each repeating monomer group,and a heteroatom either incorporated in the heterocyclic ring orpositioned along the backbone in a position adjacent the aromatic ring.The heteroatom can be located directly on the backbone or bonded to acarbon atom which is positioned directly on the backbone. In both caseswhere the heteroatom is located on the backbone or bonded to a carbonatom positioned on the backbone, the backbone atom is positioned on thebackbone adjacent to an aromatic ring. Non-limiting examples of thepolymers used in this aspect of the invention can be selected from thegroup including PPS, Poly(p-phenylene oxide)(“PPO”), LCPs, Polyetherether ketone (“PEEK”), Polyphthalamide (“PPA”), Polypyrrole,Polyaniline, and Polysulfone. Co-polymers including monomers of thelisted polymers and mixtures of these polymers may also be used. Forexample, copolymers of p-hydroxybenzoic acid can be appropriate liquidcrystal polymer base polymers.

Table 1 details non-limiting examples of reactant polymers useful in thesynthesis of the solid ionically conductive polymer material along withmonomer structure and some physical property information which should beconsidered also non-limiting as polymers can take multiple forms whichcan affect their physical properties.

TABLE 1 Melting Polymer Monomer Structure Pt. (C.) MW PPS polyphenylenesulfide

285 109 PPO Poly(p- phenylene oxide)

262  92 PEEK Polyether ether ketone

335 288 PPA Polyphthalamide

312 Polypyrrole

Polyaniline Poly- Phenylamine [C₆H₄NH]_(n)

385 442 Polysulfone

240 Xydar (LCP)

Vectran Poly- paraphenylene terephthalamide [—CO—C₆H₄—CO—NH—C₆H₄—NH—]_(n)

Polyvinylidene fluoride (PVDF)

177° C. Polyacrylonitrile (PAN)

300° C. Polytetrafluoro- ethylene (PTFE)

327 Polyethylene (PE)

115-135

Dopants that are useful as reactants in the synthesis of the solidionically conductive polymer material are electron acceptors oroxidants. It is believed that the dopant acts to release ions for ionictransport and mobility, and it is believed to create a site analogous toa charge transfer complex or site within the polymer to allow for ionicconductivity. Non-limiting examples of useful dopants are quinones suchas: 2,3-dicyano-5,6-dichlorodicyanoquinone (C₈Cl₂N₂O₂) also known as“DDQ”, and tetrachloro-1,4-benzoquinone (C₆Cl₄O₂), also known aschloranil, tetracyanoethylene (C₆N₄) also known as TCNE, sulfur trioxide(“SO₃”), ozone (trioxygen or O₃), oxygen (O₂, including air), transitionmetal oxides including manganese dioxide (“MnO₂”), or any suitableelectron acceptor, etc. and combinations thereof. Dopants that aretemperature stable at the temperatures of the synthesis heating step areuseful, and quinones and other dopants which are both temperature stableand strong oxidizers quinones are very useful. Table 2 provides anon-limiting listing of dopants, along with their chemical diagrams.

TABLE 2 Dopant Formula Structure 2,3-Dichloro- 5,6-dicyano-1,4-benzoquinone (DDQ) C₆Cl₂(CN)₂O₂

tetrachloro-1,4- benzoquinone (chloranil) C₆Cl₄O₂

Tetracyanoethylene (TCNE) C₆N₄

Sulfur Trioxide SO₃ Ozone O₃ Oxygen O₂ Transition Metal Oxides MxO_(y)(M = Transition Metal, x and y are equal to or greater than 1)

Ionic compounds that are useful as reactants in the synthesis of thesolid ionically conductive polymer material are compounds that releasedesired lithium ions during the synthesis of the solid ionicallyconductive polymer material. The ionic compound is distinct from thedopant in that both an ionic compound and a dopant are required.Non-limiting examples include Li₂O, LiOH, LiNO₃, LiTFSI (lithiumbis-trifluoromethanesulfonimide), LiFSI (Lithiumbis(fluorosulfonyl)imide), Lithium bis(oxalato)borate (LiB(C₂O₄)₂“LiBOB”), lithium triflate LiCF₃O₃S (lithium trifluoromethanesulfonate), LiPF6 (lithium hexafluorophosphate), LiBF4 (lithiumtetrafluoroborate), LiAsF6 (lithium hexafluoroarsenate) and otherlithium salts and combinations thereof. Hydrated forms (e.g.monohydride) of these compounds can be used to simplify handling of thecompounds. Inorganic oxides, chlorides and hydroxide are suitable ioniccompounds in that they dissociate during synthesis to create at leastone anionic and cationic diffusing ion. Any such ionic compound thatdissociates to create at least one anionic and cationic diffusing ionwould similarly be suitable. Multiple ionic compounds can also be usefulthat result in multiple anionic and cationic diffusing ions can bepreferred. The particular ionic compound included in the synthesisdepends on the utility desired for the material. For example, in anaspect where it would be desired to have a lithium cation, a lithiumhydroxide, or a lithium oxide convertible to a lithium and hydroxide ionwould be appropriate. As would be any lithium containing compound thatreleases both a lithium cathode and a diffusing anion during synthesis.A non-limiting group of such lithium ionic compounds includes those usedas lithium salts in organic solvents.

The purity of the materials is potentially important so as to preventany unintended side reactions and to maximize the effectiveness of thesynthesis reaction to produce a highly conductive material.Substantially pure reactants with generally high purities of the dopant,base polymer and the ionic compound are useful, and purities greaterthan 98% are more useful with even higher purities, e.g. LiOH: 99.6%,DDQ: >98%, and Chloranil: >99% also useful.

To further describe the utility of the solid ionically conductivepolymer material and the versatility of the above described method ofthe synthesis of the solid ionically conductive polymer material, use ofthe solid ionically conductive polymer material in certain aspects oflithium metal electrochemical applications are described:

Referring to FIG. 1 there is shown the battery 10 of an aspect in across sectional view. The battery includes both a cathode 20 and ananode 30. The cathode is positioned adjacent or is attached to a cathodecurrent collector 40 which can act to conduct electrons to the cathode.The anode 30 is similarly positioned adjacent or is attached to an anodecurrent collector 50 which also acts to conduct electrons from the anodeto an external load. Interposed between the anode 30 and the cathode 20is the solid polymer electrolyte 60 which acts both as a dielectriclayer preventing electrical conduction and internal shorts between theanode and cathode while ionically conducting ions between the anode andcathode.

The described battery components are similar to typical batterycomponents however the solid polymer electrolyte and its combinationwith each battery component is further described in aspects of thelithium cell.

The anode current collector 50 is electrically conducting and positionedadjacent the solid polymer electrolyte film 60. Interposed between theanode current collector and the solid polymer electrolyte is an anodewhich can comprise any of the multiple typical lithium intercalationmaterials or lithium metal. Upon charge the solid polymer electrolyteacts to conduct lithium metal to the anode, and to the lithiumintercalation material in an aspect, or to the anode current collectorif lithium metal is used. In the aspect of a lithium metal anode excesslithium can be added to the cell and is maintained at the anodecollector and can act as a deposition surface upon cell charging.

In the aspect when an anode intercalation material is used as the anodeelectrochemically active material, useful anode materials includetypical anode intercalation materials comprising: lithium titanium oxide(LTO), Silicon (Si), germanium (Ge), and tin (Sn) anodes doped andundoped; and other elements, such as antimony (Sb), lead (Pb), Cobalt(Co), Iron (Fe), Titanium (Ti), Nickel (Ni), magnesium (Mg), aluminum(Al), gallium (Ga), Germanium (Ge), phosphorus (P), arsenic (As),bismuth (Bi), and zinc (Zn) doped and undoped; oxides, nitrides,phosphides, and hydrides of the foregoing; and carbons (C) includingnanostructured carbon, graphite, graphene and other materials includingcarbon, and mixtures thereof. In this aspect the anode intercalationmaterial can be mixed with and dispersed within the solid ionicallyconducting polymer material such that the solid ionically conductingpolymer material can act to ionically conduct the lithium ions to andfrom the intercalation material during both intercalation anddeintercalation (or lithiation/delithiation).

In the aspect when lithium metal is used, the lithium can be added withthe cathode material, added to the anode as lithium foil, dispersed inthe solid ionically conducting polymer material, or added to bothbattery components.

The solid polymer electrolyte acts to transport the lithium metal to andfrom the anode and therefore must be positioned within the battery so itis enabled to do so. Thus the solid polymer electrolyte can bepositioned as a film layer in a planar or jellyroll batteryconstruction, a convolute positioned around the anode current collector,or any other shape which enables the solid polymer electrolyte toperform its lithium ion conduction. The thickness of the solid polymerelectrolyte can be in a desired range of uniform thicknesses such as 200to 25 micrometers or thinner. To aid in extrusion of the solid polymerelectrolyte, a rheological or extrusion aid can be added such as EPDM(ethylene propylene diene monomer) in amounts necessary to affect thedesired extrusion properties.

The cathode current collector 40 is also a typical aluminum or otherelectrically conducting film onto which the cathode 20 can be located orpositioned.

Typical electrochemically active cathode compounds which can be usedinclude but are not limited to: NCA—Lithium Nickel Cobalt Aluminum Oxide(LiNiCoAlO₂); NCM (NMC)—Lithium Nickel Cobalt Manganese Oxide(LiNiCoMnO₂); LFP—Lithium Iron Phosphate (LiFePO₄); LMO—LithiumManganese Oxide (LiMn₂O₄); LCO—Lithium Cobalt Oxide (LiCoO₂); lithiumoxides tor phosphates that contain nickel, cobalt or manganese, andLiTiS2, LiNiO2, and other layered materials, other spinels, otherolivines and tavorites, and combinations thereof. In an aspect, theelectrochemically active cathode compounds can be an intercalationmaterial or a cathode material that reacts with the lithium in a solidstate redox reaction. Such conversion cathode materials include: metalhalides including but not limited to metal fluorides such as FeF₂, BiF₃,CuF₂, and NiF₂, and metal chlorides including but not limited to FeCl₃,FeCl₂, CoCl₂, NiCl₂, CuCl₂, and AgCl; Sulfur (S); Selenium (Se);Tellerium (Te); Iodine (I); Oxygen (O); and related materials such asbut not limited to pyrite (FeS₂) and Li₂S. As the solid polymerelectrolyte is stable at high voltages (exceeding 5.0V relative theanode electrochemically active material), an aspect is to increase theenergy density by enabling as high a voltage battery as possible,therefore high voltage cathode compounds are preferred in this aspect.Certain NCM or NMC material can provide such high voltages with highconcentrations of the nickel atom. In an aspect, NCMs that have anatomic percentage of nickel which is greater than that of cobalt ormanganese, such as NCM₅₂₃, NCM₇₁₂, NCM₇₂₁, NCM₈₁₁, NCM₅₃₂, and NCM₅₂₃,are useful to provide a higher voltage relative the anodeelectrochemically active material.

EXAMPLES

The battery article and its components are described here, and ways tomake and use them are illustrated in the following examples.

Example 1

PPS and chloranil powder are mixed in a 4.2:1 molar ratio (base polymermonomer to dopant ratio greater than 1:1). The mixture is then heated inargon or air at a temperature up to 350° C. for about twenty-four (24)hours at atmospheric pressure. A color change is observed confirming thecreation of charge transfer complexes in the polymer-dopant reactionmixture. The reaction mixture is then reground to a small averageparticle size between 1-40 micrometers. LiTFSI powder (12 wt. % of totalmixture) is then mixed with the reaction mixture to create thesynthesized solid, ionically conducting polymer material. The solid,ionically conducting polymer material which is used as a solid polymerelectrolyte in this aspect is referred to as a solid polymer electrolytewhen thus used.

The solid polymer electrolyte can be used in multiple locations in abattery, including in an electrode, or as a standalone dielectric,non-electrochemically active electrolyte interposed between electrodes.When so used, the solid polymer electrolyte can be the same material inall battery application, and in the aspect of a lithium battery if theionic mobility of lithium is maximized, this property and attribute ofthe solid polymer electrolyte allows the solid polymer electrolyte tofunction well in an anode, cathode and as a standalone dielectric,non-electrochemically active electrolyte interposed between anode andcathode electrodes. However, in an aspect, the solid polymer electrolytecan vary so as to accommodate different properties that may be desiredin an application. In a non-limiting example, an electronicallyconductive material could be added to the solid polymer electrolyte orintegrated into the solid polymer electrolyte during its synthesis thusincreasing the electrical conductivity of the solid polymer electrolyteand making it suitable for use in an electrode and reducing and oreliminating the need for additional electrical conductive additives insuch an electrode. If so used, such a formulation would not beappropriate for use as a standalone dielectric, non-electrochemicallyactive electrolyte interposed between anode and cathode electrodes as itis electrically conductive and would act to short the battery.

Further, use of the solid polymer electrolyte in an anode, cathode andas a standalone dielectric, non-electrochemically active electrolyteinterposed between anode and cathode electrodes enables a batterydesigner to take advantage of the thermoplastic nature of the solidpolymer electrolyte. The standalone dielectric, non-electrochemicallyactive electrolyte can be thermoformed onto the anode or cathode bybeing heated and fixed thereto, such as in a lamination process, or bybeing co-extruded and thus formed together with the electrode. In anaspect all three battery components include the solid polymerelectrolyte and are thermoformed together or coextruded to form abattery.

Electronic conductivity of the synthesized material is measured usingpotentiostatic method between blocking electrodes, and was determined tobe 6.5×10⁻⁹ S/cm or less than 1×10⁻⁸ S/cm.

Diffusivity measurements were conducted on the synthesized material.PGSE-NMR measurements were made using a Varian-S Direct Drive 300 (7.1T) spectrometer. Magic angle spinning technique was used to average outchemical shift anisotropy and dipolar interaction. Pulsed gradient spinstimulated echo pulse sequence was used for the self-diffusion(diffusivity) measurements. The measurements of the self-diffusioncoefficients for the cation and anion in each material sample were madeusing ¹H and ⁷Li nuclei, respectively. The material cation diffusivity D(⁷Li) of 0.23×10⁻⁹ m²/s at room temperature, and the anion diffusivity D(¹H) of was 0.45×10 m²/s at room temperature.

In order to determine the degree of ion association which would decreasethe conductivity of the material, the conductivity of the material iscalculated via the Nemst-Einstein equation, using the measured diffusionmeasurements, it was determined the associated calculated conductivityto be much greater than the measured conductivity. The difference was onaverage at least an order of magnitude (or 10×). Therefore, it isbelieved that conductivity can be improved by improving iondissociation, and the calculated conductivities can be considered withinthe range of conductivity.

The cation transference number can be estimated via equation (1) fromthe diffusion coefficient data as:t+˜D+/(D++D−)  (1)

where D+ and D− refer to the diffusion coefficients of the Li cation andTFSI anion, respectively. From the above data, one obtains a t+ value ofabout 0.7 in the solid ionically conductive polymer material. Thisproperty of high cation transference number has important implicationsto battery performance. Ideally one would prefer a t+ value of 1.0,meaning that the Li ions carry all the electric current. Anion mobilityresults in electrode polarization effects which can limit batteryperformance. The calculated transference number of 0.7 is not believedto have been observed in any liquid or PEO based electrolyte. Althoughion association may affect the calculation, electrochemical resultsconfirm the transference number range of between 0.65 and 0.75.

It is believed that the t+ is dependent on anion diffusion as lithiumcation diffusion is high. As the cation diffusion is greater than thecorresponding anion diffusion the cation transference number is alwaysabove 0.5, and as the anion is mobile the cation transference numbermust also be less than 1.0. It is believed that a survey of lithiumsalts as ionic compounds would produce this range of cation transferencenumbers greater than 0.5 and less than 1.0. As a comparative example,some ceramics have been reported to have high diffusion numbers, howeversuch ceramics only transport a single ion, therefore the cationtransference number reduces to 1.0 as the D− is zero.

Example 2

Lithium cobalt oxide (LiCoO₂)(“LCO”) cathodes were prepared containingthe synthesized material from Example 1. The cathodes used a loading of70% LCO by weight which is mixed with the solid ionically conductivepolymer material and an electrically conducting carbon. Cells wereprepared using lithium metal anodes, porous polypropylene separator anda standard Li-ion liquid electrolyte composed of LiPF₆ salt andcarbonate-based solvents. The cells were assembled in a dry glovebox andcycle tested.

The capacity in terms of the weight in grams of LCO used in these cellsis displayed in FIG. 2. It can be seen that the capacity was stable whencharged to 4.3 V, and consistent with the target of 0.5 equivalents ofLi removed from the cathode during charging. The cell was also cycled toa higher charge voltage of 4.5V, which utilizes a higher percentage oflithium from the cathode, and resulted in the high capacity of >140mAh/g. The slight drop in capacity with cycle number observed for the4.5V charge tests is consistent with decomposition (i.e. non-stable) ofthe liquid electrolyte at this higher voltage. Overall, the performanceof the LCO cathode containing the material of the present invention isfavorably comparable to a slurry coated LCO cathode.

Example 3

Additional solid ionically conductive polymer materials are listing inTable 3, along with the material synthesized and described in Example 1(PPS-Chloranil-LiTFSI), which were prepared using the synthesis methodof Example 1, along with their reactants and associated ionicconductivity (EIS method) at room temperature.

TABLE 3 Ionic Poly- Con- mer ductivity (base) Dopant Ionic Compound (Wt%) (S/cm) PPS Chloranil LiTFSI (12) 6.0E-04 PPS Chloranil LiTFSI (4)LiBOB(1) 2.2E-04 PPS Chloranil LiTFSI (10) LiBOB(1) 7.3E-04 PPSChloranil LiTFSI (10) LiBOB(1) 5.7E-04 PPS Chloranil LiFSI (10) LiBOB(1)8.8E-04 PPS Chloranil LiTFSI (5) LiFSI (5) LiBOB(1) 1.3E-03Various physical properties of the solid ionically conductive polymermaterials are measured and it is determined that the solid ionicallyconductive polymer materials: the electronic area specific resistance isgreater than 1×10⁵ Ohm-cm²; can be molded to thicknesses from 200micrometers down to 20 micrometers; possesses significant ionic mobilityto very low temperatures, e.g. −40° C., and have ionic conductivities atroom temperature greater than 1.0E-05 S/cm, 1.0E-04 S/cm, and 1.0E-03S/cm, and these ionic conductivities include lithium as one of themobile ions being conducted through the solid ionically conductivepolymer material.

Example 4

To demonstrate the ability of the solid polymer electrolyte to becombined with a lithium ion electrochemically active material, anodeswere prepared with materials such as graphite (meso-carbon micro beads),silicon, tin, and lithium titanate (Li₄Ti₅O₁₂, LTO). These materialswere chosen for evaluation since they are currently either being used incommercially available Li-ion cells, or are actively being researchedfor application to Li-ion anodes. In each case, solid polymerelectrolyte material was added to the active anode material and an anodewas prepared. These anodes were then tested by cycling versus a lithiummetal anode with polypropylene separator and standard liquidelectrolyte. Results of this testing are presented in FIGS. 3 and 4.FIG. 3 displays a cycle test of a Tin anode combined with the solidpolymer electrolyte. The Li/Sn and solid polymer electrolyte coin cellis discharged at a constant current of 0.5 mA, and charged at a constantcurrent of 0.2 mA. FIG. 4 displays a cycle test of a Graphite anodecombined with the solid polymer electrolyte. The Li/Graphite and solidpolymer electrolyte coin cell is discharged at a constant current of 0.5mA, and charged at a constant current of 0.2 mA.

In each case, the solid polymer electrolyte was found to be compatiblewith the anode materials and demonstrates the utility of the solidpolymer electrolyte in preparing both cathodes and anodes for lithiumion cells. Furthermore, the solid polymer electrolyte has been shown tobe stable either as a stand-alone ionically conductive electrolyte andseparator, or in combination with standard Li-ion separator and liquidelectrolyte. This flexibility in cell design provides an advantage tobattery manufacturers where the battery chemistry, design and overallcell performance can be tailored to meet specific device requirements.

Example 5

To demonstrate the solid polymer electrolyte is stable at and can enablehigh voltage batteries, coin cells were constructed using lithium metalanodes. The solid polymer electrolyte is cut into a disk to completelycover a lithium metal disk, and a titanium metal disk is used as ablocking electrode. The coin cell of this Li/ solid polymer electrolyte(“SPE”)/Ti construction was prepared in an Argon-filled glovebox withvery low water content, to prevent the reaction of the lithium electrodewith moisture.

The Li/SPE/Ti coin cell was then placed on cyclic voltammetry (CV) test,where the voltage of the cell is varied at a constant scan rate (in thiscase, 2 mV/sec) between set voltage limits of −0.5V and 5.5V. Thecurrent is measured for the cell and plotted as a function of thevoltage, as displayed in FIG. 5, which displays cyclic voltammetry ofthe Li/SPE/Ti cell, at a scan rate of 2 mV/sec, cycled between thevoltage limits of −0.5 V and 5.5 V. This test is useful to simulate theuse of the SPE in a high voltage cell in which the charged batteryvoltage extends upwards greater than 4.2 V and up to at least 5.5V.

As can be seen in the cyclic voltammetry curve in FIG. 5, there arestrong anodic and cathodic waves, near 0 V, which are attributed to theplating and stripping of lithium metal. Below 0 V, the negative currentindicates that lithium metal is plating onto the stainless steel disk.Slightly above 0 V, the positive current is due to the stripping-off oflithium metal from the stainless steel disk. These waves are veryimportant in that they demonstrate the ability of the solid polymerelectrolyte to transfer lithium ions through the electrolyte, which isnecessary for the operation of any lithium anode secondary battery. Justas important as the Li plating and stripping waves, is the absence ofother waves in the CV curve. This test demonstrates that the polymerelectrolyte is stable within this voltage window (up to or exceeding 5.5V) and would be similarly stable in a battery where the charged oroperating voltage extends to 5.5V or greater.

Typical Lithium ion (“Li-Ion”) batteries are limited in voltage range bythe liquid electrolytes used in these systems. Li-ion electrolytestypically containing carbonate-based solvents, for example: propylenecarbonate, ethylene carbonate, dimethyl carbonate, diethyl carbonate,ethyl methyl carbonate, etc., limit the positive voltage of the battery.Typically, batteries of this nature can only be charged to 4.3 V,because the liquid electrolyte starts to oxidize and decompose abovethis potential. The use of the solid polymer electrolyte inlithium-based batteries enables charging to a higher voltage, which inturn will increase the amount of energy stored in the battery and leadto longer battery run-time. Charging to a higher voltage will alsoenable the use of higher voltage cathodes, such as lithium cobaltphosphate, NCM and other new cathode materials for lithium ion cellsthat have electrochemical potentials relative lithium metal greater than4.3V. The research on these new high voltage cathodes has been hinderedby a lack of stable electrolytes at voltages greater than 4.3 V. Thesolid polymer electrolyte solves this problem by providing a lithium ionconductive electrolyte which is stable at high voltages.

Comparative Example 6

As a comparison to the cyclic voltammetry displayed in FIG. 5, aCurrent-Voltage (“CV”) curve was measured for a Li/Stainless Steel cellcontaining liquid electrolyte (EC-DMC-DEC and VC with LiPF₆ salt) and apolypropylene separator (from Celgard). The curve is displayed in FIG.6.

As can be seen in the CV curve for the liquid electrolyte comparisonexample, a cathodic peak appears on the positive scan (as indicated bythe arrow) which is attributed to the decomposition of the liquidelectrolyte at a voltage above 4 V. This comparison shows that theliquid electrolyte is prone to decomposition, while the polymerelectrolyte is stable at high voltage and does not decompose, asillustrated in Example 5.

Example 7

Referring to FIG. 7, there is shown a test battery with the solidpolymer electrolyte interposed between two strips of lithium metal. TheLi/ solid polymer electrolyte /Li cells were constructed in an inertatmosphere and lithium was transferred by applying constant current tothe cell for a period of time (in this example, the period of time was 1h). The current was then reversed and the lithium was transferred in theopposite direction. FIG. 8 shows a plot of the voltage V relative timeof a cell with >320 charge-discharge cycles, using a current density of0.5 mA/cm² and tested at room temperature. In this example, the currentis held constant and the voltage is measured, as can be seen on they-axis of FIG. 8. The voltage displayed by the cell during the constantcurrent test depends on the polarization of the cell, which is relatedto the overall resistance of the cell (i.e. the higher the resistance ofthe cell, the larger the change in voltage, or higher polarization). Theoverall resistance of the cell is due to the bulk resistance of thesolid polymer electrolyte plus the interfacial resistance of the polymerelectrolyte in contact with the lithium metal surfaces. The FIG. 8 plotshows that the polarization of the cell is relatively constant for theentire test. The results of this test further demonstrates the stabilityof the polymer electrolyte, where 1565 microns of lithium weretransferred over the entire test, and the lithium metal electrodes wereonly about 85 microns in thickness to begin. These results demonstratethat the solid polymer electrolyte has the capability to transfer largeamounts of lithium with high stability. FIG. 8 plot voltage is above 1.0V as the cell is put in series with a NiMH cell during testing.

Example 8

To demonstrate the utility of the solid polymer electrolyte in highvoltage batteries, cells were constructed using lithium metal anodes (20micrometers or less in thickness), solid polymer electrolyte and lithiumcobalt oxide cathodes containing the solid polymer electrolyte. Thelithium cobalt oxide, LiCoO₂ (“LCO”), is used since this is a highvoltage cathode material with a charged voltage over 4 V. The use oflithium metal anodes increases the energy density of the battery, sincelithium metal has much higher capacity than a lithiated graphiteelectrode that is typically used in a Li-ion battery. The theoreticalcapacity of lithiated graphite is 372 mAh/g, while lithium metal has acapacity of 3860 mAh/g—more than ten times the capacity of graphiteanodes. Coin cells of the Li/SPE/LCO configuration were cycle tested anddemonstrated good performance, as displayed in FIG. 9, which showselectrochemical impedance spectroscopy (EIS) of the bipolar Li/SPE/LiBattery. FIG. 9 shows the EIS initially, the EIS after 1 month ofstorage, after 2 months of storage, and after 3 months of storage.

The capacity of the LiCoO₂ used in these cells was 134 mAh/g, whichcorresponds to the target 0.5 equivalents of Li removed from the cathodeduring charging. The cycling efficiency for lithium was found to be over99%, which matches or exceeds that found for liquid electrolyte systems.Cycling efficiency is calculated by counting coulombs over a singlecycle and comparing the charge and discharge cycles to calculate theefficiency ((charge out/charge into battery) times 100). Overall, theseresults demonstrate the function of the solid polymer electrolyte as anelectrolyte for high voltage lithium-based battery systems.

The density of the lithium deposited onto the anode current collectorduring battery charging was measured and determined to be greater than0.4 g/cc.

Example 9

The stability of the Li/ solid polymer electrolyte /LCO cells weretested on open circuit storage. This test utilized fully charged Li/SPEsolid polymer electrolyte LCO cells, as described in Example 8, andstored the cells for a two-week period at room temperature. The cellsdisplayed good voltage stability, as displayed in FIG. 10. Following the2 weeks of open circuit storage, the cells were fully discharged and thedischarge capacity was compared to the cell performance prior tostorage. Both cells displayed 84 to 85% of pre-storage discharge(greater than 80%), demonstrating low self-discharge during the two-weekstorage, and further demonstrating the stability of the high voltageLi/SPE/LCO battery system.

Example 10

The solid polymer electrolyte of Example 3, specificallyPPS/Chloranil/LiTFSI-LiFSI-LiBOB, was used to make a secondary lithiumcell. The cell comprised a lithium metal anode, the solid polymerelectrolyte was interposed between the anode and a slurry cathode. Theslurry cathode also comprised the solid polymer electrolyte and thecathode is manufactured using a stepwise process. The process initiallyincludes a polyvinylidene difluoride (PVDF) binder in a solvent such asN-Methyl-2-pyrrolidone (NMP) or Dimethylacetamide (DMA). Electricallyconductive carbon and graphite and the solid polymer electrolyte arethen added in a first mixing step in which the carbon and solid polymerelectrolyte remain stable and insoluble in the binder solvent. Thisfirst mixture is then mixed in a second mixing step with aelectrochemically active cathode material such as Lithium cobalt oxide(LiCoO₂)(“LCO”) to create a slurry mix which is then coated onto acathode collector. After a drying step in which the binder solvent isdriven out of the cathode, the cathode is calendared to create a highdensity cathode.

Table 4 details composition ranges for each of the cathode componentsincluded in the described slurry cathode process.

TABLE 4 Cathode Component Wt. % Electrochemically Active Material 70-90Solid Polymer Electrolyte  4-15 Electrically conductive carbon 1-5Electrically conductive graphite 1-5 Binder 3-5

The high density cathode is about 15 to 115 micrometers in thickness,and has a cathode coating density in the range of 1.2 to 3.6 g/cc.

The high density cathode is then added to the described secondarylithium cell and displays significant performance. Specifically, thelithium cell displays voltage stability above 5.0V to at least 5.5V(greater than 4.1V and 4.5 V); the lithium metal can be cycled throughthe solid polymer electrolyte a rates greater than 0.5 mA/cm², 1.0mA/cm² and to at least 1.5 mA/cm² at room temperature, while also beingable to cycle lithium in excess of an areal capacity of 3.0 mAh/cm² forgreater than 10 cycles, and greater than 18.0 mAh/cm²; being cycled forgreater than 150 cycles at 1.0 mA/cm² and 0.25 mAh/cm²; having greaterthan 80% depth of discharge of the lithium anode (i.e. fraction of thelithium metal present that is cycled, and over 70% depth of dischargefor at least 10 cycles at 0.5 mA/cm² and 3 mAh/cm²; and produces platedlithium on the anode current collector greater than 0.45 g/cc (greaterthan 0.4 g/cc) thus maintaining battery volume with little to noswelling.

While the invention has been described in detail herein in accordancewith certain aspects thereof, many modifications and changes therein maybe affected by those skilled in the art without departing from thespirit of the invention. Accordingly, it is our intent to be limitedonly by the scope of the appending claims and not by way of the detailsand instrumentalities describing the embodiments shown herein.

It is to be understood that variations and modifications can be made onthe aforementioned structure without departing from the concepts of thepresent invention, and further it is to be understood that such conceptsare intended to be covered by the following claims unless these claimsby their language expressly state otherwise.

What is claimed is:
 1. A battery comprising: an anode comprising a firstelectrochemically active material; a cathode comprising both a secondelectrochemically active material and a first electrolyte; and a secondelectrolyte interposed between the anode and the cathode; wherein atleast one of the first electrolyte and the second electrolyte comprisesa solid polymer electrolyte; wherein the solid polymer electrolyte has aglassy state, and comprises both at least one cationic diffusing ion andat least one anionic diffusing ion; wherein at least one of the at leastone cationic diffusing ions comprises lithium; wherein at least one ofthe at least one cationic diffusing ion and the at least one of theanionic diffusing ion is mobile in the glassy state; and wherein thefirst electrochemically active material comprises a lithium metal;wherein the glassy state extends in a range of temperatures of the solidpolymer electrolyte from a melting temperature of the solid polymerelectrolyte to a temperature lower than the melting temperature; andwherein at least one of the at least one cationic diffusing ion and theat least one anionic diffusing ion has a diffusivity of greater than1.0×10⁻¹² m²/s.
 2. The battery of claim 1, wherein an electronicconductivity of the solid polymer electrolyte is less than 1×10-8 S/cmat room temperature.
 3. The battery of claim 1, wherein a meltingtemperature of the solid polymer electrolyte is greater than 250° C. 4.The battery of claim 1, wherein the solid polymer electrolyte is athermoplastic.
 5. The battery of claim 1, wherein an ionic conductivityof the solid polymer electrolyte is isotropic.
 6. The battery of claim1, wherein the solid polymer electrolyte is non-flammable.
 7. Thebattery of claim 1, wherein the Young's modulus of the solid polymerelectrolyte is equal to or greater than 3.0 MPa.
 8. The battery of claim1, wherein an ionic conductivity of the solid polymer electrolyte isgreater than 1.0×10⁻⁵ S/cm at room temperature.
 9. The battery of claim1, wherein the solid polymer electrolyte comprises a single cationicdiffusing ion; wherein the at least one of the at least one singleanionic diffusing ion comprises lithium; and wherein a diffusivity ofthe single cationic diffusing ion is greater than 1.0×10⁻¹² m²/s at roomtemperature.
 10. The battery of claim 1, wherein the solid polymerelectrolyte comprises a single anionic diffusing ion; and wherein adiffusivity of the single anionic diffusing ion is greater than1.0×10⁻¹² m²/s at room temperature.
 11. The battery of claim 1, whereinat least one of the at least one anionic diffusing ion and the at leastone cationic diffusing ion has a diffusivity greater than 1.0×10⁻¹²m²/s.
 12. The battery of claim 1, wherein the solid polymer electrolytehas an ionic conductivity greater than 1×10⁻⁴ S/cm at room temperature.13. The battery of claim 1, wherein the solid polymer electrolyte has anionic conductivity greater than 1×10⁻³ S/cm at 80° C.
 14. The battery ofclaim 1, wherein the solid polymer electrolyte has an ionic conductivitygreater than 1×10⁻⁵ S/cm at −40° C.
 15. The battery of claim 1, whereina concentration of lithium is greater than 3 moles of lithium per literof solid polymer electrolyte.
 16. The battery of claim 1, wherein the atleast one cationic diffusing ion has a cationic diffusivity and the atleast one anionic diffusing ion has an anionic diffusivity; and whereinthe cationic diffusivity is greater than the anionic diffusivity. 17.The battery of claim 1, wherein a cationic transference number of thesolid polymer electrolyte is greater than 0.5 and less than 1.0.
 18. Thebattery of claim 1, wherein the at least one anionic diffusing ion ismonovalent.
 19. The battery of claim 1, wherein at least one anionicdiffusing ion comprises fluorine or boron.
 20. The battery of claim 1,wherein there is at least one mole of the lithium per liter of solidpolymer electrolyte.
 21. The battery of claim 1, wherein the solidpolymer electrolyte further comprises a heteroatom incorporated in aring structure or positioned on a backbone adjacent the ring structure.22. The battery of claim 21, wherein the heteroatom is selected from thegroup consisting of sulfur, oxygen and nitrogen.
 23. The battery ofclaim 21, wherein the heteroatom is sulfur.
 24. The battery of claim 1,wherein the solid polymer electrolyte comprises a plurality of monomers;and wherein a molecular weight of each monomer is greater than 100grams/mole.
 25. The battery of claim 1, wherein the solid polymerelectrolyte comprises: a plurality of monomers; and a plurality ofcharge transfer complexes; wherein each of the plurality of chargetransfer complexes is positioned on a corresponding monomer, wherein anelectronic conductivity of the solid polymer electrolyte is less than1×10'S/cm at room temperature; wherein each of the plurality of chargetransfer complexes is formed by a reaction of a polymer, an electronacceptor, and an ionic compound; and wherein each of the at least onecationic diffusing ion and the at least one anionic diffusing ion is areaction product of the ionic compound.
 26. The battery of claim 1,wherein the solid polymer electrolyte is formed from at least one ioniccompound; and wherein the ionic compound comprises each of the at leastone cationic diffusing ion and the at least one anionic diffusing ion.27. The battery of claim 1, wherein the solid polymer electrolytebecomes ionically conductive after being doped by an electron acceptorin the presence of an ionic compound that either contains the at leastone cationic diffusing ion and the at least one anionic diffusing ion oris convertible into both the at least one cationic diffusing ion and theat least one anionic diffusing ion via reaction with the electronacceptor.
 28. The battery of claim 1, wherein the solid polymerelectrolyte is formed from a reaction product of a base polymer, anelectron acceptor and an ionic compound.
 29. The battery of claim 28,wherein the base polymer is a conjugated polymer.
 30. The battery ofclaim 28, wherein the base polymer is Polyphenylene Sulfide (PPS) or aliquid crystal polymer.
 31. The battery of claim 1, wherein both thefirst electrolyte and the second electrolyte comprise the solid polymerelectrolyte; and wherein an electronic conductivity of the secondelectrolyte is less than 1×10⁻⁸ S/cm at room temperature.
 32. Thebattery of claim 1, wherein both the first electrolyte and the secondelectrolyte comprise the solid polymer electrolyte.
 33. The battery ofclaim 1, wherein the anode comprises a third electrolyte; and whereinthe third electrolyte comprises the solid polymer electrolyte.
 34. Thebattery of claim 1, wherein the second electrolyte comprises the solidpolymer electrolyte and is formed into a film; and wherein the thicknessof the film is between 200 and 15 micrometers.
 35. The battery of claim1, wherein the second electrochemically active material comprises anintercalation material.
 36. The battery of claim 1, wherein the secondelectrochemically active material comprises a lithium oxide comprising acomponent selected from the group consisting of nickel, cobalt,manganese, and a combination of at least two of the aforementioned. 37.The battery of claim 1, wherein the second electrochemically activematerial has an electrochemical potential greater than 4.2 voltsrelative lithium metal.
 38. The battery of claim 1, wherein the cathodehas an electrode potential greater than 4.2 volts relative lithiummetal.
 39. The battery of claim 1, wherein the second electrochemicallyactive material is intermixed with an electrically conductive materialand the solid polymer electrolyte.
 40. The battery of claim 39, whereinthe electrically conductive material comprises carbon.
 41. The batteryof claim 1, wherein the cathode comprises 70-90 percent by weight of thesecond electrochemically active material.
 42. The battery of claim 1,wherein the cathode comprises 4-15 percent by weight of the solidpolymer electrolyte.
 43. The battery of claim 1, wherein the cathodecomprises 2-10 percent by weight of an electrically conductive material.44. The battery of claim 43, wherein the electrically conductivematerial comprises carbon.
 45. The battery of claim 1, wherein thecathode is formed from a slurry.
 46. The battery of claim 1, wherein thecathode is positioned on a cathode collector.
 47. The battery of claim1, wherein the second electrochemically active material comprises alithium oxide or a lithium phosphate, each of the lithium oxide or thelithium phosphate containing nickel, cobalt or manganese.
 48. Thebattery of claim 1, wherein the second electrochemically active materialcomprises an intercalation material; and wherein the intercalationmaterial comprises lithium.
 49. The battery of claim 48, wherein thelithium intercalation material comprises at least one material selectedfrom the group consisting of Lithium Nickel Cobalt Aluminum Oxide,Lithium Nickel Cobalt Manganese Oxide, Lithium Iron Phosphate, LithiumManganese Oxide, Lithium Cobalt Phosphate, Lithium Manganese NickelOxide, Lithium Cobalt Oxide, LiTiS2, LiNiO2, and a combination of atleast two of the aforementioned materials.
 50. The battery of claim 1,wherein the second electrochemically active material comprises anelectrochemically active cathode compound that reacts with lithium in asolid state redox reaction.
 51. The battery of claim 50, wherein theelectrochemically active cathode material comprises a material selectedfrom the group consisting of a metal halide, Sulfur, Selenium,Tellurium, Iodine, Pyrite (FeS₂) and Li₂S.
 52. The battery of claim 50,wherein the lithium intercalation material comprises Lithium NickelCobalt Manganese Oxide; and wherein an atomic concentration of nickel inthe Lithium Nickel Cobalt Manganese Oxide is greater than an atomicconcentration of cobalt or manganese.
 53. The battery of claim 1,wherein the first electrochemically active material comprises anintercalation material.
 54. The battery of claim 53, wherein the anodefurther comprises the solid polymer electrolyte; and wherein the firstelectrochemically active material is mixed with the solid polymerelectrolyte.
 55. The battery of claim 1, further comprising an anodecurrent collector in ionic communication with the anode; wherein lithiumdeposits on the anode current collector when the battery is charged. 56.The battery of claim 55, wherein a density of the lithium deposited onthe anode current collector is greater than 0.4 g/cc.
 57. The battery ofclaim 1, further comprising an anode current collector in ioniccommunication with the anode; wherein the electrolyte is positionedadjacent the anode current collector.
 58. The battery of claim 54,wherein the first electrochemically active material comprises Silicon,Tin, antimony, lead, Cobalt, Iron, Titanium, Nickel, Magnesium,Aluminum, Gallium, Germanium, Phosphorus, Arsenic, Bismuth, Zinc,Carbon, and a mixture of at least two of the aforementioned.
 59. Thebattery of claim 1, wherein the second electrochemically active materialcomprises an intercalation material.
 60. The battery of claim 59,wherein the charged voltage of the battery is greater than 4.1 volts.61. The battery of claim 59, wherein the charged voltage of the batteryis greater than 4.5 volts.
 62. The battery of claim 59, wherein thecharged voltage of the battery is greater than 5.0 volts.
 63. Thebattery of claim 1, wherein lithium is cycled between the anode andcathode at a rate greater than 0.5 mA/cm² at room temperature.
 64. Thebattery of claim 1, wherein lithium is cycled between the anode andcathode at a rate greater than 1.0 mA/cm² at room temperature.
 65. Thebattery of claim 55, wherein the lithium is cycled between the anode andcathode for greater than 150 cycles.
 66. The battery of claim 1, whereinlithium is cycled between the anode and cathode at a rate greater than3.0 mAh/cm² at room temperature for greater than ten cycles.
 67. Thebattery of claim 1, wherein lithium is cycled between the anode andcathode at a rate greater than 18.0 mAh/cm².
 68. The battery of claim 1,wherein lithium is cycled between the anode and cathode at a rategreater than 0.25 mAh/cm² at room temperature for greater than 150cycles.
 69. The battery of claim 1, further comprising an anode currentcollector, wherein lithium is plated onto the anode current collectorwhen the battery is charged; and wherein a density of the lithium platedonto the anode current collector is greater than 0.4 g/cc.
 70. Thebattery of claim 1, wherein the lithium cycling efficiency is greaterthan 99%.
 71. The battery of claim 1, wherein the second electrolytecomprises the solid polymer electrolyte and is formed into a film; andwherein the first electrolyte comprises the solid polymer electrolyte,whereby the second electrolyte is attached to the cathode.
 72. Thebattery of claim 1, wherein the second electrolyte comprises the solidpolymer electrolyte and is formed into a film; wherein the anodecomprises a third electrolyte; and wherein the third electrolytecomprises the solid polymer electrolyte, whereby the second electrolyteis attached to the anode.